Systems, methods, and products for creating gas atomized metal matrix composite-based feedstock for cold spray

ABSTRACT

Implementations provide gas atomized metal matrix composite (“GAMMC”)-based feedstock for cold spray additive manufacturing (“CSAM”) enabling complex structural repairs. The feedstock is prepared by arranging a metal matrix composite (MMC) material in a gas atomization system, wherein the MMC material includes metal particles and ceramic particles. The feedstock is further prepared by performing gas atomization of the MMC material using the gas atomization system to atomize the MMC material, and producing a feedstock powder comprised of metal particles that are embedded with the ceramic particles from the atomized MMC material. The GAMMC-based feedstock comprises metallic (for binding to the substrate of the damaged part) and ceramic (for reinforcement) particles bonded together such that the ceramic particles bond directly to and within the metallic particles. GAMMC-based feedstock strengthens the repaired part and prevents degradation of the mechanical properties of the repaired part below stock specifications.

BACKGROUND

Cold spray additive manufacturing (“CSAM”) is usable to repair parts ofvehicles and other items suffering corrosion or certain other damage.However, the feedstock material used in conventional CSAM (“traditionalCSAM”) is not sufficiently robust to meet the current commercial needsfor such repair. In particular, while such parts are reparable usingconventional CSAM, the resulting repaired parts often exhibit inferiormechanical properties to equivalent undamaged parts. Inferior mechanicalproperties render repaired parts unsuitable for use in applicationsrequiring the parts to have stock mechanical properties (for instance,to meet specifications for proper functioning and safety).

Cold spray feedstock powder is typically of the same or similar chemicalcomposition as the substrate alloy under repair. However, conventionalCSAM generates and affixes to the repaired part a layer of materialhaving reduced mechanical properties compared with the substrate of thepart, due at least in part to use of conventional CSAM feedstock. Insome conventional CSAM using industry best practices, repaired parts:(1) lose approximately twenty to twenty-five percent ultimate tensilestrength; and (2) exhibit a fifty to seventy percent drop instrain-to-failure measurements relative to the original undamaged part.

When metal matrix composites (“MMC” or “MMCs”) are created by or used insuch conventional CSAM feedstock, metallic and ceramic powders orparticles are mixed together, and the ceramic particles (forreinforcement) do not bond to the metallic particles (for bonding to thesubstrate). Instead, conventional CSAM feedstock is comprised of aplurality of metal particles having a plurality of surfaces, withceramic particles fixed to the plurality of surfaces. Even beforeapplication to a part, conventional CSAM feedstock possesses inferiormechanical properties to the original undamaged substrate of a part.While CSAM strengthens the part under repair, this lack of bondingdegrades the structural integrity of the repaired part. Using thisconventional CSAM MMC feedstock generates interface defects between thesubstrate of the part and the applied feedstock and lowers the overallperformance and mechanical properties of the repaired part.

Some conventional CSAM uses heat treatment of the MMC feedstock toattempt to ameliorate these deficiencies. However, heat treatment cannotput the mechanical properties of the repaired part on par with themechanical properties of an undamaged part. Thus, without a betterperforming MMC feedstock, the range of materials repairable by CSAM in acommercially practicable fashion is limited, and the commercial use ofCSAM is therefore constrained.

SUMMARY

Some implementations provide a gas atomization system for producing afeedstock powder for cold spraying. The gas atomization system includesan intake sub-system configured to receive a metal matrix composite(MMC) material. The MMC material comprises metal particles and ceramicparticles. The gas atomization system further includes an atomizersub-system configured to conduct gas atomization of the MMC material.The atomizer sub-system includes a heating unit configured to heat theMMC material to a temperature for gas atomization; a pressurization unitconfigured to apply a gas stream at a gas pressure for gas atomization;and a flow regulation unit configured to maintain a metal flow rate forgas atomization. The gas atomization includes atomizing the MMC materialat the gas pressure and the metal flow rate; while maintaining thetemperature of the MMC material; and producing the feedstock powdercomprised of the metal particles that are embedded with the ceramicparticles from the atomized MMC material.

Other implementations provide a method for producing feedstock for coldspraying. The method includes arranging a metal matrix composite (MMC)material in a gas atomization system. The MMC material comprises metalparticles and ceramic particles. The method further includes performinggas atomization of the MMC material using the gas atomization system toatomize the MMC material; and producing a feedstock powder comprised ofmetal particles that are embedded with the ceramic particles from theatomized MMC material.

Still other implementations provide a feedstock for cold sprayingprepared by a process. The process includes arranging a metal matrixcomposite (MMC) material in a gas atomization system. The MMC materialcomprises metal particles and ceramic particles. The process furtherincludes performing gas atomization of the MMC material using the gasatomization system to atomize the MMC material; and producing afeedstock powder comprised of metal particles that are embedded with theceramic particles from the atomized MMC material.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. The foregoing Summary, as well as the following DetailedDescription of certain implementations, will be better understood whenread in conjunction with the appended drawings. This Summary is notintended to identify key features or essential features of the claimedsubject matter, nor is it intended to be used as an aid in determiningthe scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings,wherein:

FIG. 1 is a block diagram illustration of a gas atomization system inaccordance with an implementation.

FIG. 2 is a flowchart illustrating a method for producing feedstock forcold spraying in accordance with an implementation.

FIG. 3 is a flowchart illustrating another method for producingfeedstock for cold spraying in accordance with an implementation.

FIG. 4 is an illustration of an EDS X-ray map showing mechanical mixingbetween a cold sprayed material and a substrate of a part subject to aCSAM-based process in accordance with an implementation.

FIG. 5 is a block diagram illustrating an operating environment showingan implementation of a system for performing cold spray additivemanufacturing in accordance with an implementation.

FIG. 6 is a flow chart illustrating a method for aircraft manufacturingand service in accordance with an implementation.

FIG. 7 is a schematic perspective view of an aircraft in accordance withan implementation.

FIG. 8 is a functional block diagram illustrating a computing apparatusin accordance with an implementation.

Corresponding reference characters indicate corresponding partsthroughout the drawings in accordance with an implementation.

DETAILED DESCRIPTION

Cold spray additive manufacturing (also “cold spray” or “CSAM” herein)is a material-deposition process where metal or metal-ceramic mixturesof powders (also referred to as “particles” herein) suspended in a gaspropelled at supersonic speed are used to form a coating or freestandingstructure. Specifically, cold spraying is defined herein as spraying amaterial at a temperature that is below the melting point of thematerial being sprayed. CSAM is a solid state process: neither thepowders nor the substrate to which the powders are applied are meltedduring the process. Thus, use of CSAM provides material-deposition thatdoes not cause thermally induced alterations to the substrate or powder(e.g., deformation, crystallization, imperfections, or other types ofdamage). Due to the direct impingement of the gases carrying the powdersupon the substrate, cold spray generates a stationary shock wave andalso a lateral flow of gas along the surface of the part subject toCSAM.

High- and low-pressure cold spray is an emerging technology findingincreasing applications in various types of structural repairs. In someimplementations, cold spray is usable to repair metallic structures(e.g., airplane or helicopter components). An example of animplementation of a CSAM apparatus and process is provided in thediscussion of FIG. 5 herein.

Referring to the figures, implementations of the disclosure includesystems, methods, and products for creating gas atomized metal matrixcomposite (“GAMMC” or “GAMMCs”)-based feedstock for CSAM. The quality ofCSAM-based repairs, and in particular the mechanical properties of apart subject to CSAM-based repair, are dependent on the feedstock used.GAMMC-based feedstock is more robust than and possesses mechanicalproperties sufficiently superior to conventional or traditional CSAMfeedstock to enable CSAM to meet the current need for commerciallypracticable CSAM-based repair across a wider variety of parts ofvehicles and other items. In some implementations, parts repaired viaCSAM using GAMMC-based feedstock exhibit mechanical properties at leastequal to or superior to the mechanical properties of the part in anundamaged state. In other implementations, parts repaired via CSAM usingGAMMC-based feedstock retain sufficiently robust mechanical propertiesthat such parts remain suitable for use in applications requiring theparts to have at least stock mechanical properties (for instance, tomeet specifications for proper functioning and safety). Further, in someimplementations, in comparison to parts repaired using conventional CSAMfeedstock, parts repaired via CSAM using GAMMC-based feedstock do notexhibit: (1) a loss of at least twenty percent of the ultimate tensilestrength (“UTS”) relative to the original undamaged parts; or a fifty toseventy percent drop in strain-to-failure (“STF”) measurements relativeto the original undamaged parts.

When GAMMC-based feedstock is created for CSAM, metallic and ceramicpowders or particles are bonded together such that the ceramic particles(for reinforcement) bond directly to the metallic particles (for bindingto the substrate), instead of the ceramic particles merely being affixedto surface of the metallic particles as in traditional CSAM feedstock.GAMMC-based feedstock thus has superior mechanical properties totraditional CSAM feedstock before use. Use of GAMMC-based feedstock inCSAM applications thus both strengthens the part and, via this bonding,and prevents degradation of structural integrity by maintaining (or insome implementations improving) the mechanical properties of thesubstrate of the repaired part, such that the mechanical propertiesremain sufficiently robust. Such repaired parts thus remain suitable foruse in applications requiring the parts to have at least stockmechanical properties. Using GAMMC-based feedstock in CSAM applicationsalso reduces (or in some implementations, avoids completely) thegeneration of interface defects between the substrate of the part andthe applied feedstock, while at least maintaining the overallperformance and mechanical properties of the repaired part. In thecontext of this disclosure, an interface defect between two surfaces(e.g., the surface of the substrate of the part and the surface of thecold sprayed feedstock particles) refers to flaws in the bonding betweenthose surfaces. Such interface defects negatively impact mechanicalproperties.

The elements described herein in various implementations operate in anunconventional manner to provide systems, methods, and products forcreating GAMMCs for CSAM by improving the mechanical properties of thefeedstock used in CSAM applications. Such improvement enables complexstructural repairs of devices, vehicles (e.g., aircraft, watercraft,land vehicles, etc.), and buildings that are infeasible withconventional CSAM feedstock. GAMMC-based feedstock facilitates bondingbetween the substrate of a part and the cold sprayed GAMMC-basedfeedstock through a metallic surface in the GAMMC-based feedstockpowder. Ceramic particle reinforcement intimately attached to theinterior of the GAMMC-based feedstock particles further enhances themechanical properties of the GAMMC-based feedstock.

Further, GAMMC-based feedstock does not require the use of heattreatment specifically to attempt to lessen the degradation ofmechanical properties of the feedstock on application to a part duringCSAM-based repairs. Use of GAMMC-based feedstock in CSAM-based repairsis more effective in maintaining the mechanical properties of therepaired part than heat treating traditional CSAM feedstock before use.

Additionally, GAMMC-based feedstock simplifies the supply chain of arepairer by virtue of being usable on a wider variety of parts subjectto repair and allows repairers to make new types of repairs available(e.g., new service SKUs in the commercial repair context). CSAM-basedrepairs using GAMMC-based feedstock enable the manufacture of higherperformance parts than are manufacturable by traditional CSAM techniquesusing traditional CSAM feedstock. In some implementations, GAMMC-basedfeedstock provides a ten KSI improvement in UTS. While there is thus noneed for feedstock particle size optimization or CSAM processoptimization to achieve UTS improvement, some implementations includeoptional further optimization of feedstock particle size or the CSAMprocess to achieve further UTS improvements, other mechanicalproperty-related benefits, general quality control improvements, orother similar benefits.

The implementations of the present disclosure are thus superior totypical implementations of systems, methods, and products for creatingconventional CSAM feedstock that fail completely to address thedegradation of mechanical properties and the associated restriction inuseful repair applications endemic to the resultant traditional CSAMfeedstock. In some implementations, the performance of implementationsof the systems, methods, and products for creating gas atomized metalmatrix composites for cold spray disclosed herein, as measured by themechanical properties of either the disclosed GAMMC-based feedstock orparts repaired via CSAM using the disclosed GAMMC-based feedstocksubstantially equals and sometimes exceeds conventional existingcontemporary the systems, methods, and products for creating traditionalCSAM feedstock that introduce inherent and unavoidable loss ordegradation of mechanical properties as discussed elsewhere herein.

The GAMMC-based feedstock is thus mechanically more robust and more costeffective to implement, while at the same time being more effective thanconventional systems, methods, and products for creating traditionalCSAM feedstock for cold spray at producing a GAMMC-based feedstock whosemechanical properties render the GAMMC-based feedstock commerciallypracticable for a wider variety CSAM-based repair applications thantraditional CSAM feedstock.

Referring particularly to FIG. 1, this figure is a block diagramillustration of a gas atomization system 100 in accordance with animplementation. Gas atomization is a technique whereby high qualitymetallic powders are manufactured. In some implementations of gasatomization, molten metal is atomized using jets of inert gas, resultingin fine droplets of molten metal. The droplets descend down an atomizingtower. The droplets cool during the descent, resulting in metallicpowder. Some implementations of gas atomization result in powders havinga perfectly spherical shape, a high cleanliness level, and enhancedmechanical properties compared to metallic powders created using otheratomization techniques.

Implementations of the gas atomization system 100 produce a feedstockpowder 150 for cold spraying. In some implementations, the feedstockpowder 150 is a GAMMC-based feedstock powder. The gas atomization system100 comprises an intake sub-system 102 configured to receive a metalmatrix composite (MMC) material 108. The MMC material 108 comprisesmetal particles 110 and ceramic particles 112. In some implementations,the MMC material 108 is a bar stock of decorated metal powder 128 thathas been consolidated. The bar stock of decorated metal powder 128 hasthe ceramic particles 112 on an outside surface 130 of the metalparticles 110 thereof. In some such implementations, the ceramicparticles 112 comprise nanoparticles or microparticles 132 of at leastone of aluminum oxide or titanium diboride.

The gas atomization system 100 further comprises an atomizer sub-system104 configured to conduct gas atomization of the MMC material 108. Theatomizer sub-system 104 comprises a heating unit 114 configured to heatthe MMC material 108 to a temperature 116 for gas atomization; apressurization unit 118 configured to apply a gas stream 120 at a gaspressure 122 for gas atomization; and a flow regulation unit 124configured to maintain a metal flow rate 126 for gas atomization. Thegas atomization comprises atomizing the MMC material 108 at the gaspressure 122 and the metal flow rate 126, while maintaining thetemperature 116 of the MMC material 108. The gas atomization producesthe feedstock powder 150 comprised of the metal particles 110 that areembedded with the ceramic particles 112 from the atomized MMC material108. In some implementations, the temperature 116 is in a range from themelting temperature of the MMC material 108 to the melting temperatureof the MMC material 108 plus 300 degrees Celsius; the gas pressure 122is in a range of 10-30 bars (e.g., 10 bars, 11 bars, 12 bars, etc.); andthe metal flow rate 126 is in a range of 0.2 to 2 kilograms per minute(e.g., 0.2, 0.3, 0.4, etc. kilograms per minute). However, other valuesand ranges are contemplated. For example, the melting temperature can bethe melting temperature of the MMC material 108 plus 290-310 degreesCelsius. The gas atomization comprises, for example, at least one of anon-cold spray gas atomizing process or a cold spray gas atomizingprocess.

In some implementations, the gas atomization system 100 furthercomprises an output sub-system 106 configured to output the feedstockpowder 150 to a cold spray system 160 in a secondary consolidation step.In some such implementations, the cold spray system 160 gas atomizes thesupplied feedstock powder 150.

The gas atomization system 100 or the cold spray system 160 furthercomprises an induction driven gas atomizer configured to atomize a barof feedstock. In such implementations of the gas atomization system 100,the MMC material 108 received by the intake sub-system 102 isconsolidated into a bar using a secondary consolidation step. Usablesecondary consolidation steps include, but are not limited to, sparkplasma sintering (“SPS”) or extrusion. The consolidated bar is then gasatomized by the atomizer sub-system 104 to produce a feedstock powder150 with a more homogeneous distribution of particles than, e.g., thebar stock of decorated metal powder 128.

In some other implementations, the gas atomization system 100 or thecold spray system 160 is configured to conduct melted pool gasatomization of the MMC material 108. Such implementations are operablewhen the MMC material 108 is in either the form of a bar or feedstockpowder. Melted pool gas atomization is faster than induction driven gasatomization, while induction driven gas atomization produces a morehomogeneous result. Whether induction driven gas atomization or meltedpool gas atomization is used depends on the needs of a particularapplication of the disclosure.

FIG. 2 is a flowchart illustrating a method 200 for producing feedstock(e.g., the GAMMC-based feedstock powder 150 of FIG. 1) for cold sprayingin accordance with an implementation. The process shown in FIG. 2 isperformed by, at least in part, a gas atomization system having anintake sub-system, an atomizer sub-system, and an output sub-system,such as the gas atomization system 100, the intake sub-system 102, theatomizer sub-system 104, and the output sub-system 106 in FIG. 1. Themethod 200 arranges a metal matrix composite (MMC) material in a gasatomization system at operation 202. The MMC material comprises metalparticles and ceramic particles. In some implementations, the MMCmaterial is a bar stock of decorated metal powder that has beenconsolidated. The bar stock of decorated metal powder has an at leastone ceramic particle on an outside surface of an at least one metalparticle thereof. In some such implementations, the ceramic particlescomprise nanoparticles or microparticles of at least one of aluminumoxide or titanium diboride.

The method 200 further performs gas atomization of the MMC materialusing the gas atomization system to atomize the MMC material atoperation 204; and produces a feedstock powder comprised of metalparticles that are embedded with the ceramic particles from the atomizedMMC material at operation 206. In some implementations, performing thegas atomization at operation 204 comprises atomizing the MMC material ata gas pressure in a range of 10-30 bars and a metal flow rate in a rangeof 0.2-2 kilograms per minute, wherein the MMC material is at atemperature in a range from the melting temperature of the MMC materialto the melting temperature of the MMC material 108 plus 300 degreesCelsius. In other implementations, the gas atomization comprises atleast one of a non-cold spray gas atomizing process or a cold spray gasatomizing process.

Thereafter, the process is complete. While the operations illustrated inFIG. 2 are performed by, at least in part, a gas atomization systemhaving an intake sub-system, an atomizer sub-system, and an outputsub-system, aspects of the disclosure contemplate performance of theoperations by other entities. In some implementations, a cloud serviceperforms one or more of the operations (e.g., by controlling theatomizer sub-system to cause gas atomization to produce the feedstockpowder).

FIG. 3 is a flowchart illustrating another method 300 for producingfeedstock (e.g., the GAMMC-based feedstock powder 150 of FIG. 1) forcold spraying in accordance with an implementation. In someimplementations, the process shown in FIG. 3 is performed by, at leastin part, a gas atomization system having an intake sub-system, anatomizer sub-system, and an output sub-system, such as the gasatomization system 100, the intake sub-system 102, the atomizersub-system 104, and the output sub-system 106 in FIG. 1. Operations 302,304, and 306 are similar to operations 202, 204, and 206 of the method200 depicted in FIG. 2, and accordingly the description will not berepeated. In some implementations, the method 300 further comprisessupplying the feedstock powder to a cold spray system in a secondaryconsolidation step at operation 308. In some implementations comprisingoperation 308, the method 300 optionally gas atomizes the suppliedfeedstock powder using the cold spray system at operation 310.

Thereafter, the process is complete. While the operations illustrated inFIG. 2 are performed by, at least in part, a gas atomization systemhaving an intake sub-system, an atomizer sub-system, and an outputsub-system, aspects of the disclosure contemplate performance of theoperations by other entities. In some implementations, a cloud serviceperforms one or more of the operations (e.g., by controlling theatomizer sub-system to cause gas atomization to produce the feedstockpowder).

FIG. 4 is an illustration of an EDS X-ray map 400 showing mechanicalmixing between a cold sprayed material and a substrate of a part subjectto a C SAM-based process in accordance with an implementation. As usedherein, each of “EDS,” “EDX,” “EDXS,” or “XEDS” refers toenergy-dispersive X-ray spectroscopy. These abbreviations areinterchangeable for purposes of this disclosure, unless otherwise noted.In some implementations, EDS is referred to as at least one of energydispersive X-ray analysis (EDXA) or energy dispersive X-raymicroanalysis (EDXMA). EDS is an analytical technique used to conductelemental analysis or chemical characterization of a sample. An EDSX-ray map (e.g., the EDS X-ray map 400) uses EDS data to presentinformation on the elemental or other material distributions within asample in graphical form. EDS X-ray maps reveal which elements or othermaterial are responsible for variations in the composition of thesample.

The EDS X-ray map 400 illustrates mechanical mixing and bonding within apart 402. The part 402 has a metallic substrate 404. During coldspray-based repair operations utilizing a GAMMC-based feedstock powder406 (e.g., the GAMMC-based feedstock powder 150 of FIG. 1), the metallicparticles within the substrate 404 mechanically mix with and bonddirectly to the GAMMC particles within the a GAMMC-based feedstockpowder 406, as described in detail elsewhere herein. The GAMMC-basedfeedstock powder 406 does not merely form a parallel layer proximate tothe substrate 404. Rather, the metallic particles within the GAMMC-basedfeedstock powder 406 are able to mechanically bond with the metallicsubstrate 404. The metallic particles within the GAMMC-based feedstockpowder 406 are reinforced with ceramic particles at least partiallyinside the metallic particles, such that the mechanical properties ofthe repaired part 402 are improved in comparison to traditionalCSAM-based repairs using traditional CSAM feedstock.

In some implementations, the GAMMC-based feedstock powder 406 is afeedstock for cold spraying prepared by a process. The process comprisesarranging an MMC material in a gas atomization system (e.g., operation202 of FIG. 2). The MMC material comprises metal particles and ceramicparticles. The process further comprises performing gas atomization ofthe MMC material using a gas atomization system to atomize the MMCmaterial (e.g., operation 204 of FIG. 2). In some implementations, thegas atomization is performed at defined operating levels, such asatomizing the MMC material at a gas pressure in a range of 10-30 barsand a metal flow rate in a range 0.2-2 kilograms per minute, wherein theMMC material is at a temperature in a range from the melting temperatureof the MMC material to the melting temperature of the MMC material plus300 degrees Celsius. In some other implementations, the gas atomizationcomprises at least one of a non-cold spray gas atomizing process or acold spray gas atomizing process.

In some implementations, the MMC material is a bar stock of decoratedmetal powder that has been consolidated; the bar stock of decoratedmetal powder having an at least one ceramic particle on an outsidesurface of an at least one metal particle thereof. In some suchimplementations, the ceramic particles comprise nanoparticles ormicroparticles of at least one of aluminum oxide or titanium diboride.The process additionally comprises producing a feedstock powdercomprised of metal particles that are embedded with the ceramicparticles from the atomized MMC material (e.g., operation 206 of FIG.2). In some implementations, use of the feedstock in cold spraying-basedrepair of a part improves mechanical properties of the repaired part.

FIG. 5 is a block diagram illustrating an operating environment showingan implementation of a system for performing cold spray additivemanufacturing in accordance with an implementation. The system 500comprises a robotic control system 502 configured to control a coldspray apparatus 504. In some implementations, the robotic control systemfurther comprises a robotic positioning arm 516 (e.g., a roboticallycontrolled mechanical arm). In some implementations, the robotic controlsystem 502 is a manual or at least partially automated apparatus. Insome such implementations, the robotic control system is controllableusing a computing device, such as the computing device 800 of FIG. 8herein. In some implementations, the robotic positioning arm 516 is atleast a five-axis positioning system that includes two axes forpositioning in a plane of the part under repair, one axis for thestandout distance, and two additional axes for additional requisitepositioning. Alternatively, the robotic positioning arm 516 is at leasta two axis positioning system for XY positioning in the plane of partunder repair and a rolling system that maintains parallelism andstandout distance with the substrate of the part under repair. Therobotic positioning arm 516, in some implementations, is an ADEPT® Viperrobot from Omron Adept Technologies, Inc. The robotic positioning arm516, in some other implementations, is another commercial device orcombination of devices having similar capabilities to the ADEPT® Viper.

The cold spray apparatus 504 of the system 500 further comprises asupersonic nozzle 535 and is configured to perform cold spray additivemanufacturing of a part 506. In some implementations, the cold sprayapparatus 504 is further configured to cold spray a powder 530 (e.g.,the feedstock powder 150 of FIG. 1) onto a substrate 551 of the part506. In such implementations, the cold spray apparatus 504 furthercomprises a source 518 of gas 512 connected to a gas control module 520.The gas control module 520 controls the flow of the gas 512 through afirst line 515 connected to the supersonic nozzle 535 and through asecond line 517 connected to a powder chamber 531 and then to thesupersonic nozzle 535. The cold spray apparatus 504 additionallycomprises a heater 525 that heats the gas 512 to a requisite temperatureprior to entrance of the gas 512 into the supersonic nozzle 535. In someimplementations, the substrate 551 is also heated to further facilitatemechanical bonding.

In operation, the gas 512 flows through the first line 515 and thesecond line 517 causing the powder 530 located within the powder chamber531 to be sprayed in a supersonic gas jet from the supersonic nozzle 535as a particle stream 540. The particle stream 540 is sprayed at atemperature below the melting point of the powder 530 and travels at asupersonic velocity from the supersonic nozzle 535. In someimplementations, the particle stream 540 travels at several times thespeed of sound. (The exact speed of sound at a given time variesdepending on local conditions). In some implementations, the particlestream 540 travels at least two- to four-times the speed of sound. Theparticle stream 540 is deposited on the substrate 551 of the part 506,whereby on impact on the substrate 551, particles of the particle stream540 undergo plastic deformation due to the supersonic velocity of theparticle stream 540 and bond to each other and the substrate 551 of thepart 506 using mechanical energy. The heater 525 accelerates the speedof the particle stream 540, but the heat from the heated gas 512 is nottransferred to the bonding of the particles of the particle stream 540.Thus, the heat cannot cause deformities, warping, stresses, or otherdeleterious impacts to the bonding. In some implementations, once thecold spray process is complete the substrate 551 is further processed,such as polished to create or restore a smooth finish. In someimplementations, the robotic positioning arm 516 is configured to avoidmaintaining a single position for so long as to transfer sufficient heatto generate heat damage on or impact the heat treatment of the substrate551.

Some implementations of the system 500 further include a feedstockintake 508. The feedstock intake 508 is configured to receive the powder530. In some implementations, the feedstock intake 508 is coupled to anoutput 510 from a gas atomization system 550, such as the outputsub-system 106 of the gas atomization system 100 of FIG. 1. Thefeedstock intake 508 in such implementations thus enables the system 500to receive GAMMC-based feedstock-based powder 530 directly from the gasatomization system, such that the GAMMC-based feedstock-based powder 530is ready for immediate use in CSAM operations.

FIG. 5 depicts, and the above paragraphs describe, implementationswherein the robotic control system 502, comprising the roboticpositioning arm 516, is configured to control the entire cold sprayapparatus 504 (a “fully-mobile robotic CSAM system”). In someimplementations (not shown in the drawings), some components of the coldspray apparatus 504 are at least partially stationary in use (a“partially-stationary robotic CSAM system” herein). In someimplementations of such partially-stationary robotic CSAM systems,during CSAM operations as described herein the robotic control system502 uses the robotic positioning arm 516 to move only the supersonicnozzle 535.

In implementations of the partially-stationary robotic CSAM system,operation of the system 500 as described above is otherwise unchanged,except that the supersonic nozzle 535 is moved by the robotic controlsystem 502 independently of the remainder of the components of the coldspray apparatus 504 and the gas atomization system 550. Whether animplementation of the disclosure utilizes the fully-mobile robotic CSAMsystem; the partially-stationary robotic CSAM system; or a combinationthereof is dependent on the needs and conditions of a particularapplication. Such needs and conditions include, but are not limited to,whether at least one of the robotic control system 502 or the cold sprayapparatus 504 are intended to be portable; the amount of open space inwhich the robotic positioning arm 516 is free to move anything attachedto the robotic positioning arm 516, and the weight-bearing or actuationcapacity of the robotic positioning arm 516.

Additional Examples

In general, there are two types of cold spray repair techniques.Non-Structural Cold Spray is concerned with adding thickness to a partor restoring geometric volume but does not provide any improvement inthe load bearing strength of the repaired part. This technology has beendeveloped and matured to the point that the United States Department ofDefense has installed Non-Structural Cold Spray repair systems at manydepots for conducting repairs including but not limited to correctingcasting defects and handling damage and wear of sealing surfaces.

Various implementations of the disclosure herein are targeted toStructural Cold Spray, which is concerned not merely with addingthickness to existing parts but reconditioning and repair of damaged,worn, or otherwise out of spec parts having load bearing capability andresponsibility. Among other applications, Structural Cold Spray issuitable to repair corrosion, repair cracks, or restore tolerances/exactdimensions. Additionally, some implementations of Structural Cold Spraydo not require stripping and reapply the finish of the part subject torepair. As disclosed herein, CSAM mechanically bonds particles to asubstrate using purely mechanical energy, with no need for addedadhesives.

Repair processes using conventional CSAM and traditional CSAM feedstockare suitable for coating restoration (e.g., replacing cladding by use ofCSAM) and non-structural dimensional restoration (restoration whereinthe cold sprayed material does not carry any load, including restorationof structural parts (e.g., gearboxes)). However, conventional CSAM andconventional CSAM feedstock are unsuitable as described elsewhere hereinfor non-critical structural repair (wherein the cold-sprayed partcarries a load and the repaired device will still operate if therepaired part fails); semi-critical structural repair (wherein the coldsprayed part carries a load and the repaired device will be damaged ormalfunction if the repaired part fails); and critical structural repairs(wherein the cold sprayed part carries a load the repaired device willbe lost or destroyed if the repaired part fails). CSAM repair processesusing some implementations of GAMMC-based feedstock as disclosed hereinare by contrast suitable for use in non-critical structural repairs,semi-critical structural repairs, and critical structural repairs,depending on the intended application.

KSI is used to measure tensile strength and other materialcharacteristics in the disclosure herein. KSI is a scaled unit derivedfrom pounds per square inch (pound-force per square inch or “psi”). Thepsi is a unit of pressure or stress based on avoirdupois units, andindicates pressure resulting from a force of one pound-force applied toan area of one square inch. One KSI is equivalent to a thousand psi. Anyother unit of measure serving the same purpose is substitutable for KSI.Other suitable units include but are not limited to kilopascals (kPa);technical atmospheres (at); standard atmospheres (atm); Torr units(torr); and bars. The unit of measure chosen for a specificimplementation depends on the needs of the intended application.

Unless explicitly stated otherwise, in some implementations, “feedstock”and “feedstock powder” are interchangeable as used herein. “Decorated”particles, as used herein, are particles with satellite particles fixedthereto. “Bar stock,” as used herein, refers in some implementations toa bar created by pressing material on a hot press and extruding thatmaterial into a bar for later manufacturing use. In some implementationsof the GAMMC-based feedstock powder disclosed herein, reinforcingdecorations (e.g., ceramic particles) are embedded inside individualmetallic particles of the feedstock powder. Such implementations of thedisclosed GAMMC-based feedstock powder avoid the negative performanceimpacts of using MMC bar stock to create non-gas atomized MMC CSAMfeedstock. In particular, impact of non-gas atomized MMC CSAM feedstockpowder during CSAM operations causes excessive and undesirous decorationoccur at the splash boundaries of the substrate and the cold sprayedfeedstock powder. Such decorations create weak areas in the cold spraylayer. These areas lack reinforcement, increasing the likelihood ofstructural failure in the repaired part.

Attempting to merely grind the MMC bar stock into powder for use inCSAM-based repairs yields similarly inferior results, as the grindingresults in misshapen (elongated) particles having boundaries between themetal and ceramic components, as well as leaving a significant anddetrimental number of ceramic particles on the surface. Such groundpowder cannot be used for CSAM without significant post-processing, andstill will not perform as well as the disclosed GAMMC-based feedstockpowder. The disclosed GAMMC-based feedstock does not have the flawsdescribed above.

Certain implementations herein utilize ceramic particles comprisingnanoparticles for reinforcement. Other implementations usemicroparticles for the same purpose. Nanoparticles are particles with asize between one and one-hundred nanometers (nm), which include aninterfacial layer integral to nanoscale matter. Microparticles areparticles with a size between one and one-thousand micrometers (μm).Whether nanoparticle or microparticle ceramic particles are utilized isdependent on the needs of a particular application of an implementation.

Thus, gas atomizing MMC bar stock during processing results in aGAMMC-based feedstock material with reinforcement inside the feedstockpowder particles, not merely upon the surface of such particles. Theceramic particles being within the metallic feedstock powder particlesenables superior bonding of the feedstock to the substrate of a partduring CSAM by providing a metallic surface prone to bonding and also ahard, ceramic particle-reinforced interior (e.g., having greaterstiffness or UTS). The reinforced material allows the feedstock powderparticles to strike the substrate harder during CSAM-based repairs,resulting in stronger bonding and an overall stronger cold spray layerupon the substrate. GAMMC-based feedstock possesses superior mechanicalproperties to conventional CSAM feedstock as discussed elsewhere herein.In some implementations, the GAMMC-based feedstock disclosed hereincomprises in part ceramic particles on the surface of the feedstockpowder particles. The presence of such surface-level particles causes nodetrimental effects to the performance of the GAMMC-based feedstock.

In some implementations, the disclosed GAMMC-based feedstock comprisesGAMMC particles as described herein, wherein the size of the GAMMCparticles is selectable. This selectable size allows suchimplementations to be tailored to specific applications. In some suchimplementations, the size of the GAMMC particles is selectable within arange of fifteen micrometers to fifty-five micrometers. In other suchimplementations, the size of the GAMMC particles is selectable within arange of twenty-five micrometers to fifty-five micrometers.

In some implementations, the disclosed GAMMC-based feedstock comprisesgas atomized metallic particles of 5056 aluminum alloy (“GAMMC 5056feedstock”). In such implementations, when used in CSAM-based repairs ofdamaged parts, GAMMC 5056 feedstock yields resultant mechanicalproperties comparable with cold spray conducted with conventionalfeedstock manufactured from 7050 aluminum alloy, particularly asmeasured by UTS and STF. In certain applications, such GAMMC 5056feedstock is suitable for use in semi-critical and critical structuralrepairs as described elsewhere herein.

In some other implementations, the disclosed GAMMC-based feedstockcomprises gas atomized metallic particles of 7050 aluminum alloy (“GAMMC7050 feedstock”). In such implementations, experimental results indicatethat the GAMMC 7050 feedstock, when used in CSAM-based repairs ofdamaged parts, results in a ten KSI increase in tensile strength incomparison to stock 7050 aluminum alloy used in undamaged parts. In suchimplementations, the disclosure thus strengthens or enhances partssubject to CSAM-based repair beyond the original stock specifications ofsuch parts.

While the GAMMC-based feedstock disclosed herein is described in thecontext of CSAM use cases, the disclosure is not limited to these usecases. The disclosed GAMMC-based feedstock is usable in any solid stateadditive manufacturing process. Other solid state additive manufacturingprocesses include but are not limited to friction stir additivemanufacturing (“FSAM”) techniques. The disclosed GAMMC-based feedstockis also useable in certain melt-based manufacturing processes.

The implementations herein provide apparatuses, methods, systems, andproducts for creating GAMMC-based feedstock for cold spray by conductinggas atomization of an MMC material received via an intake sub-systemusing an atomizer sub-system configured to conduct gas atomization ofthe MMC material to create GAMMC-based feedstock. Some implementationsof the gas atomization system incorporate an output sub-system to outputthe GAMMC-based feedstock to a cold spray system in a secondaryconsolidation step. The disclosure herein operates at the point of CSAMfeedstock preparation to create a GAMMC-based feedstock for coldspraying.

In some implementations, the produced and otherwise ready to use GAMMCfeedstock (e.g., the feedstock powder 150 of FIG. 1) is heat treated tofurther improve the mechanical properties of any CSAM-based repairconducted using the GAMMC feedstock. This heat treatment occurs afterthe disclosed gas atomization is completed and the GAMMC feedstock isstable and ready to use. Thus, any defects, deformities, and otherundesirous side effects of heat treatment as discussed herein cannotoccur.

Unless otherwise stated, any implementation described herein as beingincorporated into or being used in combination with a specific type ofvehicle (e.g., an aircraft or helicopter) shall be understood to beinstallable into and usable with any other type of vehicle (e.g.,trains, submersibles, tanks, armored personnel carriers, watercraft,etc.). Implementations of the disclosure herein are well-suited torepairing aircraft in-situ, allowing the service life of such aircraftto be maximally extended at lesser cost. Cold spray is recognized byvarious organizations as a solution distinct from and advantageous overthermal spray.

In particular, as aircraft enter the extreme ends of repeatedly extendedservice lifetimes, fleet fatigue causes cracks and other damagerequiring structural repairs, part replacement, and part repair to keepthe aircraft in service. This escalates the cost of keeping suchaircraft flying due to requiring recurrent inspections to maintain airworthiness, eventual retrofits, and long lead times and high expensesassociated with supply chain issues. Cold spray is especially wellsuited to perform these types of repairs to rehabilitate existing partsof such aircraft (e.g., repairs performed on aircraft components in anaircraft hangar without disassembly), potentially significantly reducingmaintenance costs and also lowing downtime for military aircraftplatforms. In 2008 (with revisions following in 2011 and 2015), theUnited States Department of Defense adopted and promulgated MIL SpecMIL-STD-3021 (“DOD Manufacturing Process Standard, Materials Deposition,Cold Spray”). The MIL-STD-3021 standard has been adopted by variousother organizations around the world.

The disclosure herein is usable in a number of present military andcommercial cold spray applications. Some implementations of thedisclosure have the potential to save entities operating on the scale ofthe United States Department of Defense billions of U.S. dollarsannually that would otherwise be spent on corrosion repairs. Thedisclosure also enables repair techniques for components that do notcurrently have approved repair regimens in place, allowing suchcomponents to be transitioned to a United States Department of Defensesupply base, as well as enabling certain repairs to be conducted in thefield, away from repair depots. Such military and commercial cold sprayapplications include but are not limited to:

-   -   Use by the United States Army through Maintenance Engineering        Order T-7631 by the Program Office UH-60 Blackhawk for the        repair of magnesium aerospace components;    -   Use in maintenance and repair of landing gear hydraulics for the        B1 Rockwell B-1 Lancer supersonic heavy bomber;    -   Research by the U.S. Army Research Laboratory in collaboration        with private industry for applications for additive        manufacturing as diverse as near-net forming of shape charge        liners, donor tubes for explosive cladding and sputter targets;    -   Automotive repairs;    -   Magnesium aerospace component repairs; and    -   A growing number of worldwide RDT and E programs other qualified        aerospace repair procedures worldwide.

At the time of this disclosure, in contemporary, pre-existingtraditional CSAM applications using conventional CSAM feedstock asdefined herein, the conventional CSAM feedstock and any parts repairedusing the conventional CSAM feedstock suffer issues with degradation ofmechanical properties, limiting the commercially practicableapplications of such traditional feedstock and parts repaired usingtraditional feedstock as described elsewhere herein. Without a means toimprove the mechanical properties of cold spray-based repairs, thecommercial economic viability of CSAM repair is severely curtailed.

At least a portion of the functionality of the various elements in thefigures are in some implementations performed by other elements in thefigures, and or an entity (e.g., a computer) not shown in the figures.

In some implementations, the operations illustrated in FIG. 2 and FIG. 3are performed by a single person, a group of persons, a fully- orpartially-automated system for manufacturing gas atomized metal matrixcomposites for cold spray, or any combination of the foregoing. As anillustration, in some implementations the heating unit, thepressurization unit, and the flow regulation unit are each be providedby distinct suppliers to a wholly separate assembler who couples theheating unit, the pressurization unit, and the flow regulation unit toform the atomizer sub-system.

While the aspects of the disclosure have been described in terms ofvarious implementations with their associated operations, a personskilled in the art would appreciate that a combination of operationsfrom any number of different implementations is also within scope of theaspects of the disclosure.

Exemplary Operating Environment

The present disclosure is operable within an aircraft manufacturing andservice method according to an implementation as a method 600 in FIG. 6.During pre-production of the aircraft, some implementations of method600 include specification and design of the aircraft at operation 602,and material procurement at operation 604. During production, someimplementations of method 600 include component and subassemblymanufacturing at operation 606 and aircraft system integration atoperation 608. The aircraft undergoes certification and delivery atoperation 610 in order to be placed in service at operation 612. Whilein service of a customer, the aircraft is scheduled for routinemaintenance and service at operation 614. In some implementations,operation 614 comprises modification, reconfiguration, refurbishment,and other operations associated with maintaining the aircraft inacceptable, safe condition during ongoing flight operations. Systems andmethods for cold spray additive manufacturing as disclosed herein areused during operation 614.

Each of the processes of method 600 are performable or practicable by asystem integrator, a third party, or an operator (e.g., a customer). Forthe purposes of this disclosure, a system integrator comprises anynumber of aircraft manufacturers and major-system subcontractors; athird party comprises any number of vendors, subcontractors, andsuppliers; and an operator comprises an airline, leasing company,military entity, service organization, and similar entities providingsimilar sales and leasing services.

The present disclosure is operable in a variety of terrestrial andextra-terrestrial environments for a variety of applications. Forillustrative purposes only, and with no intent to limit the possibleoperating environments in which implementations of the disclosureoperate, the following exemplary operating environment is presented. Thepresent disclosure is operable within an aircraft operating environmentaccording to an implementation as an aircraft 700 in FIG. 7.Implementations of the aircraft 700 include but are not limited to anairframe 702, a plurality of high-level systems 704, and an interior706. Some implementations of the aircraft 700 incorporate high-levelsystems 704 including but not limited to: one or more of a propulsionsystem 708, an electrical system 710, a hydraulic system 712, and anenvironmental system 714. Any number of other systems may be included inimplementations of the aircraft 700. Although an aerospaceimplementation is shown, the principles are applicable to otherindustries, such as the automotive and nautical industries.

The present disclosure is operable with a computing apparatus accordingto an implementation as a functional block diagram 800 in FIG. 8. Insuch an implementation, such as for controlling operations of componentsdescribed herein, components of a computing apparatus 818 may beimplemented as a part of an electronic device according to one or moreimplementations described in this specification. The computing apparatus818 comprises one or more processors 819 which may be microprocessors,controllers or any other suitable type of processors for processingcomputer executable instructions to control the operation of theelectronic device. Platform software comprising an operating system 820or any other suitable platform software may be provided on the apparatus818 to enable application software 821 to be executed on the device.According to an implementation, the gas atomization system for producinga feedstock powder for cold spraying as described herein may beimplemented at least partially by software.

Computer executable instructions may be provided using anycomputer-readable media that are accessible by the computing apparatus818. Computer-readable media may include, without limitation, computerstorage media such as a memory 822 and communications media. Computerstorage media, such as a memory 822, include volatile and non-volatile,removable and non-removable media implemented in any method ortechnology for storage of information such as computer readableinstructions, data structures, program modules or the like. Computerstorage media include, but are not limited to, RAM, ROM, EPROM, EEPROM,flash memory or other memory technology, CD-ROM, digital versatile disks(DVD) or other optical storage, magnetic cassettes, magnetic tape,magnetic disk storage or other magnetic storage devices, or any othernon-transmission medium that is usable to store information for accessby a computing apparatus. In contrast, communication media may embodycomputer readable instructions, data structures, program modules, or thelike in a modulated data signal, such as a carrier wave, or othertransport mechanism. As defined herein, computer storage media do notinclude communication media. Therefore, a computer storage medium shouldnot be interpreted to be a propagating signal per se. Propagated signalsper se are not examples of computer storage media. Although the computerstorage medium (the memory 822) is shown within the computing apparatus818, it will be appreciated by a person skilled in the art, that thestorage may be distributed or located remotely and accessed via anetwork or other communication link (e.g., using a communicationinterface 823).

The computing apparatus 818 may comprise an input/output controller 824configured to output information to one or more output devices 825, insome implementations a display or a speaker, which may be separate fromor integral to the electronic device. The input/output controller 824may also be configured to receive and process an input from one or moreinput devices 826, in some implementations a keyboard, a microphone or atouchpad. In one implementation, the output device 825 may also act asthe input device. A touch sensitive display is one such device. Theinput/output controller 824 may also output data to devices other thanthe output device, e.g., a locally connected printing device. In someimplementations, a user may provide input to the input device(s) 826and/or receive output from the output device(s) 825.

The functionality described herein is performable, at least in part, byone or more hardware logic components. According to an implementation,the computing apparatus 818 is configured by the program code whenexecuted by the processor 819 to execute the implementations of theoperations and functionality described. Alternatively, or in addition,the functionality described herein is performable, at least in part, byone or more hardware logic components. Without limitation, illustrativetypes of hardware logic components that are usable includeField-programmable Gate Arrays (FPGAs), Application-specific IntegratedCircuits (ASICs), Program-specific Standard Products (ASSPs),System-on-a-chip systems (SOCs), Complex Programmable Logic Devices(CPLDs), Graphics Processing Units (GPUs).

Thus, various implementations include systems, methods, and products forcreating GAMMC-based feedstock for cold spray comprising arranging ametal matrix composite (MMC) material in a gas atomization system(wherein the MMC material comprises metal particles and ceramicparticles); performing gas atomization of the MMC material using the gasatomization system to atomize the MMC material; and producing afeedstock powder comprised of metal particles that are embedded with theceramic particles from the atomized MMC material. In at least someimplementations, the produced feedstock powder is a GAMMC-basedfeedstock powder.

Various implementations described herein describe feedstock powdercomprising ceramic particles comprising at least one of aluminum oxideor titanium diboride. In such implementations, aluminum oxide ortitanium diboride are substitutable for any other type of ceramicparticle (or combinations of ceramic powders) suitable for use in CSAMas disclosed herein and further also suitable for the particularintended applications of a given implementation. This disclosure doesnot intend to exclude any type of ceramic particle unless such exclusionis explicitly stated herein.

As described herein, the present disclosure provides systems, methods,and products for creating gas atomized metal matrix composites for coldspray. The systems and methods herein efficiently and effectivelyconstruct and deploy within a cold spray additive manufacturing systemsuitable for use in connection with repairs of a number of movingvehicles, including but not limited to the above exemplary operatingenvironment.

While various spatial and directional terms, such as top, bottom, lower,mid, lateral, horizontal, vertical, front and the like may be used todescribe the present disclosure, it is understood that such terms aremerely used with respect to the orientations shown in the drawings. Theorientations may be inverted, rotated, or otherwise changed, such thatan upper portion is a lower portion, and vice versa, horizontal becomesvertical, and the like.

As used herein, a structure, limitation, or element that is “configuredto” perform a task or operation is particularly structurally formed,constructed, or adapted in a manner corresponding to the task oroperation. For purposes of clarity and the avoidance of doubt, an objectthat is merely capable of being modified to perform the task oroperation is not “configured to” perform the task or operation as usedherein.

Any range or value given herein is extendable or alterable withoutlosing the effect sought, as will be apparent to the skilled person.

As used herein, “mechanical properties” of a material refer in someimplementations to various measurable characteristics tending toindicate the likelihood that a material subject to forces (sometimescalled “loads”) while in use will either deform (e.g., elongate,compress, or twist) or otherwise break. This deformation or breakage isin some implementations a function of applied loads, time, temperature,or other physical conditions. Mechanical properties further include butare not limited to ultimate tensile strength (“UTS”), compressivestrength, sheer strength, and strain-to-failure (“STF”). Degradation inthe mechanical properties of a material results in degradation ofstructural integrity of any part comprising that material. In someimplementations, such degradation includes a loss of ductility.

UTS (also referred to as tensile strength (“TS”), ultimate strength, or“Ftu”) is the capacity of a material to withstand loads that tend toelongate (or pull apart) the material. UTS is the maximum stress amaterial can withstand under such load before deforming or breaking. UTSis measured using kilopound per square inch (kilopound/inch² or KSI)units. By comparison, compressive strength is a measurement of theability of a material to resist compression (or pushing together) beforedeforming or breaking. Compressive strength is also measurable usingKSI.

Sheer strength measures the capacity of a material to resist forcesattempting to cause at least some portion of the internal structure ofthe material to slide against at least some other portion of theinternal structure of the material. The greater the shear strength of amaterial, the less likely the material will experience structuralfailure in shear. Restated, shear strength of a material indicates theload that a material is able to withstand in a direction parallel to theface of the material, as opposed to perpendicular to the face of thematerial. Shear strength is also measurable using KSI.

STF (equivalent to elongation at break, “EAB,” or “emax”) indicates theratio between an increased length of a sample of a material and aninitial length of the same sample after breakage of the sample undertesting at a controlled temperature. (That is, STF is keyed to themaximum elongation of the sample of a material at the moment ofbreakage.) STF measurements in practice reflect the ability of amaterial to resist changes in shape without cracking or otherwisedeforming. STF is measured as a percentage or ratio—specifically, thepercent of elongation of the sample of the material versus the initiallength (or size) of the sample of the material.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexemplary forms of implementing the claims.

It will be understood that the benefits and advantages described abovecan relate to one implementation or can relate to severalimplementations. The implementations are not limited to those thataddress every issue discussed in the Background herein or those thathave any or all of the stated benefits and advantages.

The implementations illustrated and described herein as well asimplementations not specifically described herein but within the scopeof aspects of the claims constitute exemplary means for creatingGAMMC-based feedstock for CSAM.

The order of execution or performance of the operations inimplementations of the disclosure illustrated and described herein isnot essential, unless otherwise specified. That is, the operations maybe performed in any order, unless otherwise specified, and examples ofthe disclosure may include additional or fewer operations than thosedisclosed herein. As an illustration, it is contemplated that executingor performing a particular operation before, contemporaneously with, orafter another operation is within the scope of aspects of thedisclosure.

When introducing elements of aspects of the disclosure or theimplementations thereof, the articles “a,” “an,” “the,” and “said” areintended to mean that there are one or more of the elements. The terms“comprising,” “including,” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. The term “exemplary” is intended to mean “an example of” Thephrase “one or more of the following: A, B, and C” means “at least oneof A and/or at least one of B and/or at least one of C.”

Having described aspects of the disclosure in detail, it will beapparent that modifications and variations are possible withoutdeparting from the scope of aspects of the disclosure as defined in theappended claims. As various changes could be made in the aboveconstructions, products, and methods without departing from the scope ofaspects of the disclosure, it is intended that all matter contained inthe above description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

It is to be understood that the above description is intended to beillustrative, and not restrictive. As an illustration, theabove-described implementations (and/or aspects thereof) are usable incombination with each other. In addition, many modifications arepracticable to adapt a particular situation or material to the teachingsof the various implementations of the disclosure without departing fromtheir scope. While the dimensions and types of materials describedherein are intended to define the parameters of the variousimplementations of the disclosure, the implementations are by no meanslimiting and are exemplary implementations. Many other implementationswill be apparent to those of ordinary skill in the art upon reviewingthe above description. The scope of the various implementations of thedisclosure should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the respectiveterms “comprising” and “wherein.” Moreover, the terms “first,” “second,”and “third,” etc. are used merely as labels, and are not intended toimpose numerical requirements on their objects. Further, the limitationsof the following claims are not written in means-plus-function formatand are not intended to be interpreted based on 35 U.S.C. § 112(f),unless and until such claim limitations expressly use the phrase “meansfor” followed by a statement of function void of further structure.

This written description uses examples to disclose the variousimplementations of the disclosure, including the best mode, and also toenable any person of ordinary skill in the art to practice the variousimplementations of the disclosure, including making and using anydevices or systems and performing any incorporated methods. Thepatentable scope of the various implementations of the disclosure isdefined by the claims, and includes other examples that occur to thosepersons of ordinary skill in the art. Such other examples are intendedto be within the scope of the claims if the examples have structuralelements that do not differ from the literal language of the claims, orif the examples include equivalent structural elements withinsubstantial differences from the literal language of the claims.

CLAUSES

The following clauses describe further aspects:

Clause Set A:

A1. A gas atomization system for producing a feedstock powder for coldspraying, comprising:

-   -   an intake sub-system configured to receive a metal matrix        composite (MMC) material, the MMC material comprising metal        particles and ceramic particles;    -   an atomizer sub-system configured to conduct gas atomization of        the MMC material, the atomizer sub-system comprising:    -   a heating unit configured to heat the MMC material to a        temperature for gas atomization;    -   a pressurization unit configured to apply a gas stream at a gas        pressure for gas atomization;    -   a flow regulation unit configured to maintain a metal flow rate        for gas atomization; and

the gas atomization comprising:

-   -   atomizing the MMC material at the gas pressure and the metal        flow rate;    -   while maintaining the temperature of the MMC material;    -   producing the feedstock powder comprised of the metal particles        that are embedded with the ceramic particles from the atomized        MMC material.

A2. The system of any preceding clause, wherein

-   -   the temperature is in a range of a melting temperature of the        MMC material to the melting temperature of the MMC material plus        300 degrees Celsius;    -   the gas pressure is in a range of 10-30 bars; and    -   the metal flow rate is in a range of 0.2-2 kilograms per minute.

A3. The system of any preceding clause, wherein the MMC material is abar stock of decorated metal powder that has been consolidated; the barstock of decorated metal powder (128) having than at least one ceramicparticle (112) on an outside surface (130) of than at least one metalparticle (110) thereof.

A4. The system of any preceding clause, wherein the ceramic particlescomprise nanoparticles or microparticles of at least one of aluminumoxide or titanium diboride.

A5. The system of any preceding clause, further comprising an outputsub-system configured to output the feedstock powder to a cold spraysystem in a secondary consolidation step.

A6. The system of any preceding clause, wherein the cold spray systemgas atomizes the supplied feedstock powder.

A7. The system of any preceding clause, wherein gas atomizationcomprises at least one of a non-cold spray gas atomizing process or acold spray gas atomizing process.

Clause Set B:

B1. A method for producing feedstock for cold spraying, the methodcomprising:

-   -   arranging a metal matrix composite (MMC) material in a gas        atomization system, the MMC material comprising metal particles        and ceramic particles;    -   performing gas atomization of the MMC material using the gas        atomization system to atomize the MMC material; and    -   producing a feedstock powder comprised of metal particles that        are embedded with the ceramic particles from the atomized MMC        material.

B2. The method of any preceding clause, wherein the MMC material is abar stock of decorated metal powder that has been consolidated; the barstock of decorated metal powder having the at least one ceramic particleon an outside surface of the at least one metal particle thereof.

B3. The method of any preceding clause, wherein the ceramic particlescomprise nanoparticles or microparticles of at least one of aluminumoxide or titanium diboride.

B4. The method of any preceding clause, further comprising supplying thefeedstock powder to a cold spray system in a secondary consolidationstep.

B5. The method any preceding clause, wherein the cold spray system gasatomizes the supplied feedstock powder.

B6. The method of any preceding clause, wherein performing the gasatomization comprises atomizing the MMC material at a gas pressure in arange of 10-30 bars and a metal flow rate in a range of 0.2-2 kilogramsper minute, wherein the MMC material is at a temperature in a range fromthe melting temperature of the MMC material to the melting temperatureof the MMC material plus 300 degrees Celsius.

B7. The method of any preceding clause, wherein the gas atomizationcomprises at least one of a non-cold spray gas atomizing process or acold spray gas atomizing process.

Clause Set C:

C1. A feedstock for cold spraying prepared by a process comprising thesteps of:

-   -   arranging a metal matrix composite (MMC) material in a gas        atomization system, the MMC material comprising metal particles        and ceramic particles;    -   performing gas atomization of the MMC material using the gas        atomization system to atomize the MMC material; and    -   producing a feedstock powder comprised of metal particles that        are embedded with the ceramic particles from the atomized MMC        material.

C2. The feedstock prepared by any preceding process, wherein the MMCmaterial is a bar stock of decorated metal powder that has beenconsolidated; the bar stock of decorated metal powder having an at leastone ceramic particle on an outside surface of an at least one metalparticle thereof.

C3. The feedstock prepared by any preceding process, wherein the ceramicparticles comprise nanoparticles or microparticles of at least one ofaluminum oxide or titanium diboride.

C4. The feedstock prepared by any preceding process, wherein performingthe gas atomization further comprises atomizing the MMC material at agas pressure in a range of 10-30 bars and a metal flow rate in a rangeof 0.2 to 2 kilograms per minute, wherein the MMC material is at atemperature in a range from the melting temperature of the MMC materialto the melting temperature of the MMC material plus 300 degrees Celsius.

C5. The feedstock prepared by any preceding process, wherein the gasatomization comprises at least one of a non-cold spray gas atomizingprocess or a cold spray gas atomizing process.

C6. The feedstock prepared by any preceding process, wherein use of thefeedstock in cold spraying-based repair of a part improves mechanicalproperties of the repaired part.

What is claimed is:
 1. A gas atomization system for producing afeedstock powder for cold spraying, comprising: an intake sub-systemconfigured to receive a metal matrix composite (MMC) material, the MMCmaterial comprising metal particles and ceramic particles; an atomizersub-system configured to conduct gas atomization of the MMC material,the atomizer sub-system comprising: a heating unit configured to heatthe MMC material to a temperature for gas atomization; a pressurizationunit configured to apply a gas stream at a gas pressure for gasatomization; a flow regulation unit configured to maintain a metal flowrate for gas atomization; and the gas atomization comprising: atomizingthe MMC material at the gas pressure and the metal flow rate, whilemaintaining the temperature of the MMC material; and producing thefeedstock powder comprised of the metal particles that are embedded withthe ceramic particles from the atomized MMC material.
 2. The system ofclaim 1, wherein: the temperature is in a range of a melting temperatureof the MMC material to the melting temperature of the MMC material plus300 degrees Celsius; the gas pressure is in a range of 10-30 bars; andthe metal flow rate is in a range of 0.2-2 kilograms per minute.
 3. Thesystem of claim 1, wherein the MMC material is a bar stock of decoratedmetal powder that has been consolidated; the bar stock of decoratedmetal powder having an at least one ceramic particle on an outsidesurface of an at least one metal particle thereof.
 4. The system ofclaim 3, wherein the ceramic particles comprise at least one ofnanoparticles or microparticles of at least one of aluminum oxide ortitanium diboride.
 5. The system of claim 1, further comprising anoutput sub-system configured to output the feedstock powder to a coldspray system in a secondary consolidation step.
 6. The system of claim5, wherein the cold spray system gas atomizes the supplied feedstockpowder.
 7. The system of claim 1, wherein the gas atomization comprisesat least one of a non-cold spray gas atomizing process or a cold spraygas atomizing process.
 8. A method for producing feedstock for coldspraying, the method comprising: arranging a metal matrix composite(MMC) material in a gas atomization system, the MMC material comprisingmetal particles and ceramic particles; performing gas atomization of theMMC material using the gas atomization system to atomize the MMCmaterial; and producing a feedstock powder comprised of metal particlesthat are embedded with the ceramic particles from the atomized MMCmaterial.
 9. The method of claim 8, wherein the MMC material is a barstock of decorated metal powder that has been consolidated, the barstock of decorated metal powder having an at least one ceramic particleon an outside surface of the at least one metal particle thereof. 10.The method of claim 9, wherein the ceramic particles comprise at leastone of nanoparticles or microparticles of at least one of aluminum oxideor titanium diboride.
 11. The method of claim 8, further comprisingsupplying the feedstock powder to a cold spray system in a secondaryconsolidation step.
 12. The method of claim 11, wherein the cold spraysystem gas atomizes the supplied feedstock powder.
 13. The method ofclaim 8, wherein performing the gas atomization comprises atomizing theMMC material at a gas pressure in a range of 10-30 bars and a metal flowrate in a range of 0.2-2 kilograms per minute, wherein the MMC materialis at a temperature in a range from the melting temperature of the MMCmaterial to the melting temperature of the MMC material plus 300 degreesCelsius.
 14. The method of claim 8, wherein the gas atomizationcomprises at least one of a non-cold spray gas atomizing process or acold spray gas atomizing process.
 15. A feedstock for cold sprayingprepared by a process comprising the steps of: arranging a metal matrixcomposite (MMC) material in a gas atomization system, the MMC materialcomprising metal particles and ceramic particles; performing gasatomization of the MMC material using the gas atomization system toatomize the MMC material; and producing a feedstock powder comprised ofmetal particles that are embedded with the ceramic particles from theatomized MMC material.
 16. The feedstock of claim 15, wherein the MMCmaterial is a bar stock of decorated metal powder that has beenconsolidated; the bar stock of decorated metal powder having an at leastone ceramic particle on an outside surface of an at least one metalparticle thereof.
 17. The feedstock of claim 16, wherein the ceramicparticles comprise at least one of nanoparticles or microparticles of atleast one of aluminum oxide or titanium diboride.
 18. The feedstock ofclaim 15, wherein performing the gas atomization further comprisesatomizing the MMC material at a gas pressure in a range of 10-30 barsand a metal flow rate in a range of 0.2-2 kilograms per minute, whereinthe MMC material is at a temperature in a range from the meltingtemperature of the MMC material to the melting temperature of the MMCmaterial plus 300 degrees Celsius.
 19. The feedstock of claim 15,wherein the gas atomization comprises at least one of a non-cold spraygas atomizing process or a cold spray gas atomizing process.
 20. Thefeedstock of claim 15, wherein use of the feedstock in coldspraying-based repair of a part improves mechanical properties of therepaired part.